WO2007016531A2 - Apparatus and method for packaging articles - Google Patents

Apparatus and method for packaging articles Download PDF

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Publication number
WO2007016531A2
WO2007016531A2 PCT/US2006/029839 US2006029839W WO2007016531A2 WO 2007016531 A2 WO2007016531 A2 WO 2007016531A2 US 2006029839 W US2006029839 W US 2006029839W WO 2007016531 A2 WO2007016531 A2 WO 2007016531A2
Authority
WO
WIPO (PCT)
Prior art keywords
articles
conveyor means
accumulation
accumulation device
single output
Prior art date
Application number
PCT/US2006/029839
Other languages
French (fr)
Other versions
WO2007016531A3 (en
Inventor
Benoit Poutot
Original Assignee
Meadwestvaco Packaging Systems, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Meadwestvaco Packaging Systems, Llc filed Critical Meadwestvaco Packaging Systems, Llc
Publication of WO2007016531A2 publication Critical patent/WO2007016531A2/en
Publication of WO2007016531A3 publication Critical patent/WO2007016531A3/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
    • B65G47/52—Devices for transferring articles or materials between conveyors i.e. discharging or feeding devices
    • B65G47/68—Devices for transferring articles or materials between conveyors i.e. discharging or feeding devices adapted to receive articles arriving in one layer from one conveyor lane and to transfer them in individual layers to more than one conveyor lane or to one broader conveyor lane, or vice versa, e.g. combining the flows of articles conveyed by more than one conveyor
    • B65G47/70—Devices for transferring articles or materials between conveyors i.e. discharging or feeding devices adapted to receive articles arriving in one layer from one conveyor lane and to transfer them in individual layers to more than one conveyor lane or to one broader conveyor lane, or vice versa, e.g. combining the flows of articles conveyed by more than one conveyor with precedence controls among incoming article flows
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
    • B65G47/34—Devices for discharging articles or materials from conveyor 
    • B65G47/46—Devices for discharging articles or materials from conveyor  and distributing, e.g. automatically, to desired points
    • B65G47/51—Devices for discharging articles or materials from conveyor  and distributing, e.g. automatically, to desired points according to unprogrammed signals, e.g. influenced by supply situation at destination
    • B65G47/5104—Devices for discharging articles or materials from conveyor  and distributing, e.g. automatically, to desired points according to unprogrammed signals, e.g. influenced by supply situation at destination for articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
    • B65G47/52—Devices for transferring articles or materials between conveyors i.e. discharging or feeding devices
    • B65G47/68—Devices for transferring articles or materials between conveyors i.e. discharging or feeding devices adapted to receive articles arriving in one layer from one conveyor lane and to transfer them in individual layers to more than one conveyor lane or to one broader conveyor lane, or vice versa, e.g. combining the flows of articles conveyed by more than one conveyor
    • B65G47/681—Devices for transferring articles or materials between conveyors i.e. discharging or feeding devices adapted to receive articles arriving in one layer from one conveyor lane and to transfer them in individual layers to more than one conveyor lane or to one broader conveyor lane, or vice versa, e.g. combining the flows of articles conveyed by more than one conveyor from distinct, separate conveyor lanes

Definitions

  • This invention relates to packaging machines and more particularly but not exclusively to a method and apparatus for merging products from a plurality of conveyor means onto a single conveyor means.
  • Packaging machines are well known in the art. It is also well known to have several production lines operating in a single plant.
  • US 6,244,307 to Araki discloses a machine for combining parcels from tow ouch making machines having low production capacity to a single pouch filling machine having large processing capacity relate to the pouch making machines.
  • This machine comprises a single transfer mechanism to transfer articles form the input conveyors to the output conveyor.
  • the transfer mechanism switches between the input conveyors there is a 'dead time' during which period neither of the input conveyors are coupled to the output conveyor. Furthermore, during the 'dead time' no articles can be transferred to the output conveyor.
  • the transfer device disclosed in US '307 has limited storage capacity and since neither input conveyor is continuously coupled to the output conveyor must swap between input conveyors when the transfer device becomes empty thereby forcing the system disclosed in US '307 to comprise 'dead time'.
  • the system of US '307 is not capable of continuous supply from one of the input conveyors.
  • the present invention seeks to overcome or at least mitigate some of the problems of the prior art.
  • a first aspect of the invention provides a method of merging articles conveyed on at least two conveyor means onto a single conveyor means comprising: conveying articles upon a first and second conveyor means to be received at an input end of a respective first and second accumulation device, transmitting articles from the first accumulation device onto a single output conveyor means located at an output end of the first and second accumulation device, and simultaneously restraining articles from leaving the second accumulation device whilst articles are being transmitted from the first accumulation device, the restrained articles being collected in the second accumulation device whereby the second accumulation device acts as a buffer between its respective input conveyor means and the single output conveyor means, subsequently; restraining articles from leaving the first accumulator device, whereby the first accumulator device acts as a buffer between the respective input conveyor means and the single output conveyor means, and simultaneously allowing the second accumulator device to commence transmission of articles to the single output conveyor means, such that articles are continuously supplied to the single output conveyor means.
  • the method comprises changing the first accumulation device from a transmission mode to an accumulation mode when the second accumulation device reaches full storage capacity.
  • the articles alternatively the method comprises releasing in groups from the first or second accumulation device.
  • the first accumulation device the method comprises changing from a transmission mode to an accumulation mode and simultaneously changing a second accumulation device from accumulation mode to a transmission mode such that interruption of the supply of articles to the output conveyor is substantially prevented.
  • a second aspect of the invention provides an apparatus for merging articles conveyed on at least two conveyor means onto a single conveyor means, the apparatus comprising at least two input conveyor means for conveying articles, each of said at least two input conveyor means being coupled to an input end of an accumulation device respectively, and all accumulation devices being simultaneously coupled at an output end to the single output conveyor means, each accumulation device being suitable for transmitting articles to the single output conveyor means and for restraining articles from being transmitted to the single output conveyor means, each accumulation device being controlled by a control means such that one of said accumulation devices is configured to transfer articles received from the respective input conveyor means to the single output conveyor means, whereas the others of said accumulation devices being configured to restrain articles received from its respective input conveyor means from being transferred to the single output conveyor means whereby the others of said accumulation devices act as a buffer between their respective input conveyor means and the single output conveyor means, wherein the apparatus is capable of continuously supplying articles to the single output conveyor means.
  • control means instructs the transmitting accumulation device to restrain articles from being transferred to the single output conveyor means and instructs one of the restraining accumulation devices to transfer articles to the single output conveyor means.
  • the single output conveyor means operates at an article transfer rate that is at least twice that of any of the input conveyor means.
  • the single output conveyor means operates at an article transfer rate that is an integer multiple of the transfer rate of one of the input conveyor means and wherein the - A - integer multiple is equal to the number of input conveyor means supplying the single output conveyor means.
  • each input conveyor means and each accumulation device transfers articles in a direction substantially perpendicular to that of the single output conveyor means.
  • the apparatus is capable of transferring a first accumulation device from a transmission mode to an accumulation mode and simultaneously transferring a second accumulation device from an accumulation mode to a transmission mode without any substantial interruption of the supply of articles to the out put conveyor.
  • a third aspect of the invention provides a packaging system comprising a packaging machine for packing articles, wherein the packaging machine being supplied by two infeed conveyor mechanisms, each infeed conveyor mechanism being supplied articles from a pair of accumulation devices, each accumulation device being supplied articles by a respective supply means, wherein articles supplied to one of the accumulation devices of each pair of accumulation devices are transmitted to the respective infeed conveyor mechanism whereas articles supplied to the other accumulation device of each pair are restrained from being supplied to the infeed conveyor mechanism whereby each restraining accumulation device acts as a buffer between its respective supply means and its respective infeed conveyor mechanism, whereby the packing system merges articles being transferred on at least two conveyor means onto a single conveyor means.
  • the packaging system further comprises a control means coupled to each accumulation device, the control means controlling whether the accumulation devices transfers articles to the infeed conveyor mechanism or restrains the articles within in the accumulation device.
  • each of the infeed conveyor mechanisms operate at an article transfer rate at least twice that of the transfer rate of supply means.
  • the supply means and accumulation devices transfer articles in a direction substantially perpendicular to the direction that the infeed conveyor mechanisms transfer the articles.
  • each filling machine for filling the articles
  • the articles may for example be pouches, bottles or cans, with a product such as a beverage
  • each of the filling machine may supply articles to one of the supply means of each pair of supply means.
  • a device located on the supply means, for further processing of the articles such as chilling of the articles, application of straws or labels to the articles.
  • the article transfer rate of the infeed conveyor mechanisms is 250 ppm and wherein the article transfer rate of the supply means is 125 ppm.
  • the packaging machine operates at 500 ppm.
  • the system is capable of inter changing between said pair of accumulation devices to supply articles to each of said infeed conveyor mechanisms such that articles are continuously supplied to the infeed conveyor mechanism.
  • Figure 1 is a schematic view of the prior art
  • Figure 2 is a schematic view of a preferred embodiment of the present invention.
  • Figure 1 shows a schematic of production line 10 for packaging articles as currently known in the prior art.
  • Two article sources 12a, 12b are shown supplying articles 11a, lib, lie, Hd, such as bottles, cans or pouches, to four conveyor means 14a, 14b, 14c, 14d.
  • the four conveyor means 14a, 14b, 14c, 14d may then pass the articles 1 Ia, 1 Ib, 1 Ic, 1 Id through a device 16 where further processing of each of the articles 11a, lib, lie, Hd can take place, this processing may be for example; a chilling process, application of straws to the articles or labelling of the articles.
  • conveyor lines 18a, 18b, 18c, 18d at the outfeed end of the device 16 are provided to convey the articles 1 Ia, 1 Ib, 1 Ic, 1 Id to one of four respective packaging machines 20a, 20b, 20c, 2Od.
  • the present invention therefore seeks to provide a method and apparatus for merging articles travelling on a plurality of conveyor means onto a single conveyor means, which overcomes, or at least reduces the problems of the prior art. It is desirable to provide a method and apparatus for merging the articles in a simple way which substantially prevents collisions between the articles as they merge.
  • FIG. 2 shows a schematic of a production line 110 according to a preferred embodiment of the invention.
  • the production line 110 comprises two devices 112a, 112b which are sources of articles I Ha 5 111b, 111c, Hid.
  • Each article source 112a, 112b provides articles Ilia,
  • first conveyor means 114a, 114b, 114c, 114d supply the articles Ilia, HIb, 111c, Hid to a device 116, at which further processing of the articles Il ia, 11 Ib, 111c, Hid may take place.
  • the further processing may be the application of straws to pouches which have been filled with a beverage.
  • the articles IHa 5 HIb, 111c, Hid are conveyed away from the device 16 by one of four second conveyor means 118a, 118b, 118c, 118d.
  • the first and second conveyor means 114a, 114b, 114c, 114d and 118a, 118b, 118c, 118d are continuous belts.
  • Each of the second conveyors 118a, 118b, 118c, 118d supply their respective articles I l ia, 111b, 111c, Hid to an accumulator 122a, 122b, 122c, 122d provided at the out feed end of the second conveyers 118a, 118b, 118c, 118d.
  • the accumulators 122a, 122b, 122c, 122d operate in pairs to supply a third conveyor means; the accumulators 122a and 122b operate together to supply third conveyor 124a with articles H Ia, 111b whereas accumulators 122c and 122d operate together to supply third conveyor 124b with articles 111c, Hid.
  • the accumulators 122a, 122b act as a buffer between the second conveyor means 118a, 118b and the third conveyor means 124a.
  • the accumulators 122c and 122d act as a buffer between the second conveyor means 118c, 118d and the third conveyor means 124b.
  • Accumulators 122c and 122d operate in the same manner as accumulators 122a and 122b. Therefore operation of the accumulator pairs 122a, 122b and 122c, 122d will be described by reference to accumulator pair 122a, 122b only.
  • the accumulators 122a and 122b are controlled by a control means (not shown) such that only one of the accumulators 122a, 122b allows articles I l ia, 111b onto the third conveyor means 124a at any one time.
  • the accumulators 122a, 122b asynchronously supply articles
  • accumulator 122b restrains articles 111b from leaving an outfeed end of the accumulator 122b whilst at the same time allowing articles 11 Ib to enter the accumulator 122b at an infeed end thereof.
  • the accumulator 122b is in an acquisition phase when articles are collected but not transmitted.
  • the accumulator 122a is in a transmission phase when articles Ilia are transferred to the third conveyor means 124a, articles Ilia may still received by the accumulator 122a whilst in the transmission phase.
  • the control means (not shown) then instructs or configures accumulator 122a to cease supplying articles I l ia to the third conveyor means 124a and instructs or configures accumulator 122b to begin transferring articles 11 Ib to the conveyor 124a.
  • the criteria for instigating a change of mode of operation, for example moving from a collection phase to a transmission phase, of an accumulator 122a, 122b, 122c, 122d may be that no more storage capacity exists in the accumulator which is in a collection phase.
  • the criteria for changing between collection and transmission mode may be that a predetermined number of articles Il ia, 111b, 111c, H id have been transferred to the third conveyor means 124a, 124b at the out-feed end of the accumulator 122a, 122b, 122c, 122d, or the criteria may be time dependent, or it may be dependent upon the capacity of the carton or package in which the articles Il ia, 11 Ib, 111c, H id will be packaged.
  • each accumulator 122a, 122b, 122c, 122d in a pair of accumulators 122a/122b, 122c/122d could receive articles 11 Ia, 11 Ib, 11 Ic, 11 Id which are not the same, one accumulator may receive articles I lia, H Ib, 111c, IHd of a first type and the other accumulator 122a, 122b, 122c, 122d may receive articles 11 Ia, 11 Ib, 111c, 11 Id of a second type, for example; two different flavours of beverage may be contained within the articles I l ia, 111b, 111c, Hid and be conveyed separately on each line.
  • the accumulators 122a, 122b, 122c, 122d could be controlled such that the two flavours are mixed in order to provide a package containing both flavours. Or alternatively accumulators 122a, 122b, 122c, 122d could be controlled such that there is no mixing of the flavours in the package.
  • the articles Ilia, 11 Ib, 111c, Hid can therefore be grouped into batches.
  • the accumulators 122a, 122b, 122c, 122d may comprise a sensor (not shown) or other means for monitoring the articles Ilia, 11 Ib, 111c, 11 Id received by the accumulators 122a, 122b, 122c, 122d, the sensor may count the number of articles 11 Ia, 11 Ib, 11 Ic, 11 Id transferred to the third conveyor means 124a, 124b in order to group them in to batches.
  • the senor may monitor the storage capacity of the accumulators 122a, 122b, 122c, 122d such that the control means can determine when one of the accumulator 122a, 122b, 122c, 122d becomes, or will become, full.
  • the accumulators 122a, 122b, 122c, 122d may comprise a sensor, or sensors, for determining the remaining, or in alternative the used, storage capacity and in addition to a sensor for counting the articles Ilia, 111b, 111c, Hid transferred to the third conveyor means 124a, 124b
  • the conveyors means 124a, 124b as shown in the preferred embodiment of Figure 2 transfer the articles 11 Ia, 11 Ib, 11 Ic, 11 Id away from the accumulators 122a, 122b, 122c, 122d in a direction of travel perpendicular to that in the accumulators 122a, 122b, 122c, 122d.
  • the third conveyor means 124a passes past the out-feed ends of both accumulators 122a and 122b such that the accumulators 122a and 122b can both supply articles to the third conveyor means 124a.
  • a similar arrangement is employed by accumulators 122c, 122d and third conveyor means 124b. It will be noted that the length of second conveyor means 118c and 118d is shorter than that of second conveyor means 118a and 118b, this allows conveyors 124a and 124b to run substantially parallel and to feed articles into the packaging machine 120.
  • a single packaging machine 120 is employed in the preferred embodiment.
  • This packaging machine is capable packaging articles at a rate at least equal to the combined article transfer rate of the conveyors 124a and 124b ( or alternatively at least equal to the combined article transfer rate of the conveyors 118a,118b,118c,118d).
  • the article transfer rate of the third conveyor means 124a should be at least equal to the combined article transfer rate of conveyors 118a, 118b.
  • the article transfer rates of the conveyors 118a, 118b are equal, for example 112 articles per minute (products per minute, ppm), the article transfer rate of the conveyor 124a is twice that of either of the conveyors 118a,118b, for example 250 articles per minute (ppm).
  • Conveyors 118c, 118d and 124b are substantially the same as conveyors 118a, 118b and 124a, therefore the packaging machine 20 operates at twice the rate of conveyor 124a or 124b, four times that of conveyors 118a, 118b, 118c, 118d, in the examples used the packaging machine 20 operates at 500 articles per minute.
  • the conveyors 118a, 118b, 118c, 118d operate at a transfer rate below that of the transfer rate of the conveyors 124a, 124b that the accumulators 122a, 122b, 122c, 122d accelerate the articles I l ia, 111b, 111c, H id to match the speed of the third conveyor means 124a, 124b at the out feed end of the accumulators 122a, 122b, 122c, 122d.
  • the system is capable of interchanging or swapping between one of a pair of the second conveyor means 118a/l 18b, 118c/l 18d and the other of said pair of second conveyor means 118a/118b, 118c/118d without introducing dead time, time when no articles are supplied to the respective one of the third conveyor means 124a, 124b.
  • there is no interruption to the flow of articles such that articles are continuously supplied to each of the third conveyors means 124a, 124b by at least one of the second conveyors in each pair of second conveyors means 118a/l 18b, 118c/l 18d coupled to it.
  • the conveyors 124a, 124b operate at an article transfer rate twice that of the conveyors 118a, 118b, 118c, 118d. It will be appreciated that if more than two conveyors supply articles to a single conveyor then the transfer rate of the single conveyor needs to be at least an integer multiple of the transfer rate of the conveyors supplying articles to it, where the integer multiple corresponds to the number of conveyors being merged.
  • system shown in Figure 2 may comprise further accumulation devices coupled to each of the conveyor means 124a and 124b. These further accumulation devices may then supply a further conveyor means. In this way a 'daisy chain' or series of merging devices may be built up, each subsequent link in the chain operating an increased flow rate over its predecessor.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Branching, Merging, And Special Transfer Between Conveyors (AREA)
  • Attitude Control For Articles On Conveyors (AREA)

Abstract

A method of merging articles conveyed on at least two conveyors (118a, 118b) onto a single conveyor (124a), includes the steps of: conveying articles (11a, 11b) upon a first and second conveyors (118a, 118b) to a first and second accumulation devices (122a, 122b), transmitting articles (111a) from the first accumulation device (122a) onto the single conveyor (124a), preventing articles (111b) from leaving the second accumulation device (122b) whilst articles (111a) are being transmitted from the first accumulation device (122a), and preventing articles (111a) from leaving the first accumulation device (122a) whilst articles (111b) are being transmitted from the second accumulation device (122b) on to the single conveyor, such that either accumulation device (122a, 122b) acts as a buffer between the first and second conveyors and the output conveyor.

Description

APPARATUS AND METHOD FOR PACKAGING ARTICLES
Field of Invention
This invention relates to packaging machines and more particularly but not exclusively to a method and apparatus for merging products from a plurality of conveyor means onto a single conveyor means.
Background of the Invention
Packaging machines are well known in the art. It is also well known to have several production lines operating in a single plant.
It is desirable to reduce the costs and simplify production lines by reducing the number of separate packaging machines without reducing the output of the production plant.
US 6,244,307 to Araki discloses a machine for combining parcels from tow ouch making machines having low production capacity to a single pouch filling machine having large processing capacity relate to the pouch making machines.
This machine comprises a single transfer mechanism to transfer articles form the input conveyors to the output conveyor. When the transfer mechanism switches between the input conveyors there is a 'dead time' during which period neither of the input conveyors are coupled to the output conveyor. Furthermore, during the 'dead time' no articles can be transferred to the output conveyor.
The transfer device disclosed in US '307 has limited storage capacity and since neither input conveyor is continuously coupled to the output conveyor must swap between input conveyors when the transfer device becomes empty thereby forcing the system disclosed in US '307 to comprise 'dead time'. The system of US '307 is not capable of continuous supply from one of the input conveyors. The present invention seeks to overcome or at least mitigate some of the problems of the prior art.
Summary of Invention
A first aspect of the invention provides a method of merging articles conveyed on at least two conveyor means onto a single conveyor means comprising: conveying articles upon a first and second conveyor means to be received at an input end of a respective first and second accumulation device, transmitting articles from the first accumulation device onto a single output conveyor means located at an output end of the first and second accumulation device, and simultaneously restraining articles from leaving the second accumulation device whilst articles are being transmitted from the first accumulation device, the restrained articles being collected in the second accumulation device whereby the second accumulation device acts as a buffer between its respective input conveyor means and the single output conveyor means, subsequently; restraining articles from leaving the first accumulator device, whereby the first accumulator device acts as a buffer between the respective input conveyor means and the single output conveyor means, and simultaneously allowing the second accumulator device to commence transmission of articles to the single output conveyor means, such that articles are continuously supplied to the single output conveyor means.
Preferably, the method comprises changing the first accumulation device from a transmission mode to an accumulation mode when the second accumulation device reaches full storage capacity.
According to an optional feature of this aspect of the invention, the articles, alternatively the method comprises releasing in groups from the first or second accumulation device. Preferably the first accumulation device the method comprises changing from a transmission mode to an accumulation mode and simultaneously changing a second accumulation device from accumulation mode to a transmission mode such that interruption of the supply of articles to the output conveyor is substantially prevented.
A second aspect of the invention provides an apparatus for merging articles conveyed on at least two conveyor means onto a single conveyor means, the apparatus comprising at least two input conveyor means for conveying articles, each of said at least two input conveyor means being coupled to an input end of an accumulation device respectively, and all accumulation devices being simultaneously coupled at an output end to the single output conveyor means, each accumulation device being suitable for transmitting articles to the single output conveyor means and for restraining articles from being transmitted to the single output conveyor means, each accumulation device being controlled by a control means such that one of said accumulation devices is configured to transfer articles received from the respective input conveyor means to the single output conveyor means, whereas the others of said accumulation devices being configured to restrain articles received from its respective input conveyor means from being transferred to the single output conveyor means whereby the others of said accumulation devices act as a buffer between their respective input conveyor means and the single output conveyor means, wherein the apparatus is capable of continuously supplying articles to the single output conveyor means.
Preferably, the control means instructs the transmitting accumulation device to restrain articles from being transferred to the single output conveyor means and instructs one of the restraining accumulation devices to transfer articles to the single output conveyor means.
Preferably, the single output conveyor means operates at an article transfer rate that is at least twice that of any of the input conveyor means.
Alternatively, the single output conveyor means operates at an article transfer rate that is an integer multiple of the transfer rate of one of the input conveyor means and wherein the - A - integer multiple is equal to the number of input conveyor means supplying the single output conveyor means.
According to an optional feature of this aspect of the invention, each input conveyor means and each accumulation device transfers articles in a direction substantially perpendicular to that of the single output conveyor means.
According to an optional feature of this aspect of the invention, the apparatus is capable of transferring a first accumulation device from a transmission mode to an accumulation mode and simultaneously transferring a second accumulation device from an accumulation mode to a transmission mode without any substantial interruption of the supply of articles to the out put conveyor.
A third aspect of the invention provides a packaging system comprising a packaging machine for packing articles, wherein the packaging machine being supplied by two infeed conveyor mechanisms, each infeed conveyor mechanism being supplied articles from a pair of accumulation devices, each accumulation device being supplied articles by a respective supply means, wherein articles supplied to one of the accumulation devices of each pair of accumulation devices are transmitted to the respective infeed conveyor mechanism whereas articles supplied to the other accumulation device of each pair are restrained from being supplied to the infeed conveyor mechanism whereby each restraining accumulation device acts as a buffer between its respective supply means and its respective infeed conveyor mechanism, whereby the packing system merges articles being transferred on at least two conveyor means onto a single conveyor means.
Preferably the packaging system further comprises a control means coupled to each accumulation device, the control means controlling whether the accumulation devices transfers articles to the infeed conveyor mechanism or restrains the articles within in the accumulation device. Preferably, each of the infeed conveyor mechanisms operate at an article transfer rate at least twice that of the transfer rate of supply means.
According to an optional feature of this aspect of the invention, the supply means and accumulation devices transfer articles in a direction substantially perpendicular to the direction that the infeed conveyor mechanisms transfer the articles.
According to an optional feature of this aspect of the invention, there further comprises two filling machines each disposed at the infeed end of each of a pair of supply means, each filling machine for filling the articles, the articles may for example be pouches, bottles or cans, with a product such as a beverage, and wherein each of the filling machine may supply articles to one of the supply means of each pair of supply means.
Preferably, there further comprises a device located on the supply means, for further processing of the articles such as chilling of the articles, application of straws or labels to the articles.
According to an optional feature of this aspect of the invention, the article transfer rate of the infeed conveyor mechanisms is 250 ppm and wherein the article transfer rate of the supply means is 125 ppm.
Preferably the packaging machine operates at 500 ppm.
Preferably the system is capable of inter changing between said pair of accumulation devices to supply articles to each of said infeed conveyor mechanisms such that articles are continuously supplied to the infeed conveyor mechanism. Brief Description of the Drawings
An embodiment of the invention will now be described, by way of example, with reference to the accompanying drawings in which: -
Figure 1 is a schematic view of the prior art; and
Figure 2 is a schematic view of a preferred embodiment of the present invention.
Detailed Description
Figure 1 shows a schematic of production line 10 for packaging articles as currently known in the prior art.
Two article sources 12a, 12b are shown supplying articles 11a, lib, lie, Hd, such as bottles, cans or pouches, to four conveyor means 14a, 14b, 14c, 14d. The four conveyor means 14a, 14b, 14c, 14d may then pass the articles 1 Ia, 1 Ib, 1 Ic, 1 Id through a device 16 where further processing of each of the articles 11a, lib, lie, Hd can take place, this processing may be for example; a chilling process, application of straws to the articles or labelling of the articles.
Four conveyor lines 18a, 18b, 18c, 18d at the outfeed end of the device 16 are provided to convey the articles 1 Ia, 1 Ib, 1 Ic, 1 Id to one of four respective packaging machines 20a, 20b, 20c, 2Od.
One of the disadvantages of this system is that it requires maintenance of four separate packaging machines and hence greater operating costs.
The present invention therefore seeks to provide a method and apparatus for merging articles travelling on a plurality of conveyor means onto a single conveyor means, which overcomes, or at least reduces the problems of the prior art. It is desirable to provide a method and apparatus for merging the articles in a simple way which substantially prevents collisions between the articles as they merge.
Figure 2 shows a schematic of a production line 110 according to a preferred embodiment of the invention. The production line 110 comprises two devices 112a, 112b which are sources of articles I Ha5 111b, 111c, Hid. Each article source 112a, 112b provides articles Ilia,
111b, H Ic, Hid to a respective first conveyor means 114a, 114b, 114c, 114d. The first conveyor means 114a, 114b, 114c, 114d supply the articles Ilia, HIb, 111c, Hid to a device 116, at which further processing of the articles Il ia, 11 Ib, 111c, Hid may take place. For example, the further processing may be the application of straws to pouches which have been filled with a beverage.
Upon completion of the further processing the articles IHa5 HIb, 111c, Hid are conveyed away from the device 16 by one of four second conveyor means 118a, 118b, 118c, 118d. In the preferred embodiment the first and second conveyor means 114a, 114b, 114c, 114d and 118a, 118b, 118c, 118d are continuous belts. Each of the second conveyors 118a, 118b, 118c, 118d supply their respective articles I l ia, 111b, 111c, Hid to an accumulator 122a, 122b, 122c, 122d provided at the out feed end of the second conveyers 118a, 118b, 118c, 118d. The accumulators 122a, 122b, 122c, 122d operate in pairs to supply a third conveyor means; the accumulators 122a and 122b operate together to supply third conveyor 124a with articles H Ia, 111b whereas accumulators 122c and 122d operate together to supply third conveyor 124b with articles 111c, Hid. The accumulators 122a, 122b act as a buffer between the second conveyor means 118a, 118b and the third conveyor means 124a. The accumulators 122c and 122d act as a buffer between the second conveyor means 118c, 118d and the third conveyor means 124b. Accumulators 122c and 122d operate in the same manner as accumulators 122a and 122b. Therefore operation of the accumulator pairs 122a, 122b and 122c, 122d will be described by reference to accumulator pair 122a, 122b only.
The accumulators 122a and 122b are controlled by a control means (not shown) such that only one of the accumulators 122a, 122b allows articles I l ia, 111b onto the third conveyor means 124a at any one time. The accumulators 122a, 122b asynchronously supply articles
Ilia, 11 Ib to the third conveyor means 124a. When articles 11 Ia are being fed to the third conveyor means 124a by accumulator 122a, accumulator 122b restrains articles 111b from leaving an outfeed end of the accumulator 122b whilst at the same time allowing articles 11 Ib to enter the accumulator 122b at an infeed end thereof. The accumulator 122b is in an acquisition phase when articles are collected but not transmitted. The accumulator 122a is in a transmission phase when articles Ilia are transferred to the third conveyor means 124a, articles Ilia may still received by the accumulator 122a whilst in the transmission phase.
The control means (not shown) then instructs or configures accumulator 122a to cease supplying articles I l ia to the third conveyor means 124a and instructs or configures accumulator 122b to begin transferring articles 11 Ib to the conveyor 124a.
The criteria for instigating a change of mode of operation, for example moving from a collection phase to a transmission phase, of an accumulator 122a, 122b, 122c, 122d may be that no more storage capacity exists in the accumulator which is in a collection phase. In an alternative embodiment the criteria for changing between collection and transmission mode may be that a predetermined number of articles Il ia, 111b, 111c, H id have been transferred to the third conveyor means 124a, 124b at the out-feed end of the accumulator 122a, 122b, 122c, 122d, or the criteria may be time dependent, or it may be dependent upon the capacity of the carton or package in which the articles Il ia, 11 Ib, 111c, H id will be packaged. It is further possible that each accumulator 122a, 122b, 122c, 122d in a pair of accumulators 122a/122b, 122c/122d could receive articles 11 Ia, 11 Ib, 11 Ic, 11 Id which are not the same, one accumulator may receive articles I lia, H Ib, 111c, IHd of a first type and the other accumulator 122a, 122b, 122c, 122d may receive articles 11 Ia, 11 Ib, 111c, 11 Id of a second type, for example; two different flavours of beverage may be contained within the articles I l ia, 111b, 111c, Hid and be conveyed separately on each line. The accumulators 122a, 122b, 122c, 122d could be controlled such that the two flavours are mixed in order to provide a package containing both flavours. Or alternatively accumulators 122a, 122b, 122c, 122d could be controlled such that there is no mixing of the flavours in the package. The articles Ilia, 11 Ib, 111c, Hid can therefore be grouped into batches. It will be appreciated that in order to control the transfer of articles Ilia, 111b, 111c, Hid to the third conveyor means 124a, 124b the accumulators 122a, 122b, 122c, 122d may comprise a sensor (not shown) or other means for monitoring the articles Ilia, 11 Ib, 111c, 11 Id received by the accumulators 122a, 122b, 122c, 122d, the sensor may count the number of articles 11 Ia, 11 Ib, 11 Ic, 11 Id transferred to the third conveyor means 124a, 124b in order to group them in to batches. Alternatively the sensor may monitor the storage capacity of the accumulators 122a, 122b, 122c, 122d such that the control means can determine when one of the accumulator 122a, 122b, 122c, 122d becomes, or will become, full. It will be appreciated by those skilled in the art that the accumulators 122a, 122b, 122c, 122d may comprise a sensor, or sensors, for determining the remaining, or in alternative the used, storage capacity and in addition to a sensor for counting the articles Ilia, 111b, 111c, Hid transferred to the third conveyor means 124a, 124b
The conveyors means 124a, 124b as shown in the preferred embodiment of Figure 2 transfer the articles 11 Ia, 11 Ib, 11 Ic, 11 Id away from the accumulators 122a, 122b, 122c, 122d in a direction of travel perpendicular to that in the accumulators 122a, 122b, 122c, 122d. The third conveyor means 124a passes past the out-feed ends of both accumulators 122a and 122b such that the accumulators 122a and 122b can both supply articles to the third conveyor means 124a. A similar arrangement is employed by accumulators 122c, 122d and third conveyor means 124b. It will be noted that the length of second conveyor means 118c and 118d is shorter than that of second conveyor means 118a and 118b, this allows conveyors 124a and 124b to run substantially parallel and to feed articles into the packaging machine 120.
It will be appreciated by one skilled in the art that alternative arrangements could be employed. A single packaging machine 120 is employed in the preferred embodiment. This packaging machine is capable packaging articles at a rate at least equal to the combined article transfer rate of the conveyors 124a and 124b ( or alternatively at least equal to the combined article transfer rate of the conveyors 118a,118b,118c,118d). The article transfer rate of the third conveyor means 124a should be at least equal to the combined article transfer rate of conveyors 118a, 118b. In the preferred embodiment the article transfer rates of the conveyors 118a, 118b are equal, for example 112 articles per minute (products per minute, ppm), the article transfer rate of the conveyor 124a is twice that of either of the conveyors 118a,118b, for example 250 articles per minute (ppm). Conveyors 118c, 118d and 124b are substantially the same as conveyors 118a, 118b and 124a, therefore the packaging machine 20 operates at twice the rate of conveyor 124a or 124b, four times that of conveyors 118a, 118b, 118c, 118d, in the examples used the packaging machine 20 operates at 500 articles per minute. Furthermore it will be appreciated that since the conveyors 118a, 118b, 118c, 118d operate at a transfer rate below that of the transfer rate of the conveyors 124a, 124b that the accumulators 122a, 122b, 122c, 122d accelerate the articles I l ia, 111b, 111c, H id to match the speed of the third conveyor means 124a, 124b at the out feed end of the accumulators 122a, 122b, 122c, 122d.
It will be appreciated that the arrangement shown in Figure 2 is capable of continuously supplying articles from any one of the second conveyor means 118a, 118b, 118c, 118d to a respective one of the third conveyor means 124a, 124b.
Furthermore the system is capable of interchanging or swapping between one of a pair of the second conveyor means 118a/l 18b, 118c/l 18d and the other of said pair of second conveyor means 118a/118b, 118c/118d without introducing dead time, time when no articles are supplied to the respective one of the third conveyor means 124a, 124b. In this way there is no interruption to the flow of articles, such that articles are continuously supplied to each of the third conveyors means 124a, 124b by at least one of the second conveyors in each pair of second conveyors means 118a/l 18b, 118c/l 18d coupled to it.
In the preferred embodiment shown in Figure 2 the conveyors 124a, 124b operate at an article transfer rate twice that of the conveyors 118a, 118b, 118c, 118d. It will be appreciated that if more than two conveyors supply articles to a single conveyor then the transfer rate of the single conveyor needs to be at least an integer multiple of the transfer rate of the conveyors supplying articles to it, where the integer multiple corresponds to the number of conveyors being merged.
It will also be understood by one skilled in the art that the system shown in Figure 2 may comprise further accumulation devices coupled to each of the conveyor means 124a and 124b. These further accumulation devices may then supply a further conveyor means. In this way a 'daisy chain' or series of merging devices may be built up, each subsequent link in the chain operating an increased flow rate over its predecessor.

Claims

1. A method of merging articles conveyed on at least two conveyor means onto a single conveyor means comprising: conveying articles upon each of first and second conveyor means to be received at an input end of a respective one of first and second accumulation devices, transmitting articles from the first accumulation device onto a single output conveyor means located at output ends of the first and second accumulation devices, and simultaneously restraining articles from leaving the second accumulation device whilst articles are being transmitted from the first accumulation device, the restrained articles being collected in the second accumulation device whereby the second accumulation device acts as a buffer between the second conveyor means and the single output conveyor means subsequently restraining articles from leaving the first accumulation device, whereby the first accumulation device acts as a buffer between the conveyor means and the single output conveyor means, and simultaneously allowing the second accumulation device to transmit articles to the single output conveyor means, such that articles are continuously supplied to the single output conveyor means.
.
2. A method of merging articles according to claim 1, further comprising changing the first accumulation device from a transmission mode to an accumulation mode when the second accumulation device reaches full storage capacity.
3. A method of merging articles according to any one of claims 1 to 2, further comprising alternatively releasing the articles in groups from the first or second accumulation device.
4. A method of merging articles according to any one of claims 1 to 3 wherein the method comprises changing the first accumulation device from a transmission mode to an accumulation mode simultaneously changing a second accumulation device from accumulation mode to a transmission mode such that interruption of the supply of articles to the output conveyor is substantially prevented.
5. An apparatus for merging articles conveyed on at least two conveyor means onto a single conveyor means, the apparatus comprising at least two input conveyor means for conveying articles, each of said at least two input conveyor means being coupled to an input end of an accumulation device respectively, and all accumulation devices being simultaneously coupled at output ends thereof to the single output conveyor means, each accumulation device being suitable for transmitting articles to the single output conveyor means and for restraining articles from being transmitted to the single output conveyor means, each accumulation device being controlled by a control means such that one of said accumulation devices is configured to transfer articles received from the respective input conveyor means to the single output conveyor means, whereas the others of said accumulation devices being configured to restrain articles received from its respective input conveyor means from being transferred to the single output conveyor means whereby the others of said accumulation devices act as a buffer between their respective input conveyor means and the single output conveyor means, wherein the apparatus is capable of continuously supplying articles to the single output conveyor means.
6. An apparatus according to claim 5 wherein the control means instructs the transmitting accumulation device to restrain articles from being transferred to the single output conveyor means and instructs one of the restraining accumulation devices to transfer articles to the single output conveyor means.
7. An apparatus according to either one of claims 5 or 6 wherein the single output conveyor means operates at an article transfer rate that is at least twice that of any of the input conveyor means.
8. An apparatus according to any of claims 5 to 7 wherein the single output conveyor means operates at an article transfer rate that is an integer multiple of the transfer rate of one of the input conveyor means and wherein the integer multiple is equal to the number of input conveyor means supplying the single output conveyor means.
9. An apparatus according to any of claims 5 to 8 wherein each input conveyor means and each accumulation device transfers articles in a direction substantially perpendicular to that of the single output conveyor means.
10. An apparatus according to any one of claims 5 to 9 wherein the apparatus is capable of transferring a first accumulation device from a transmission mode to an accumulation mode and simultaneously transferring a second accumulation device from an accumulation mode to a transmission mode without any substantial interruption of the supply of articles to the output conveyor.
11. An apparatus for carrying out the method described in any of claims 1 -3.
12. A packaging system comprising a packaging machine for packing articles, wherein the packaging machine being supplied by two infeed conveyor mechanisms, each infeed conveyor mechanism being supplied articles from a pair of accumulation devices, each accumulation device being supplied articles by a respective supply means, wherein articles supplied to one of the accumulation devices of each pair of accumulation devices are transmitted to the respective infeed conveyor mechanism whereas articles supplied to the other accumulation device of each pair are restrained from being supplied to the infeed conveyor mechanism whereby each restraining accumulation device acts as a buffer between its respective supply means and its respective infeed conveyor mechanism, whereby the packing system merges articles being transferred on at least two conveyor means onto a single conveyor means.
13. A packaging system according to claim 12 wherein the packaging system further comprises a control means coupled to each accumulation device, the control means controlling whether the accumulation devices transfers articles to the infeed conveyor mechanism or restrains the articles within in the accumulation device.
14. A packaging system according to either one of claims 12 or 13 wherein each of the infeed conveyor mechanisms operate at an article transfer rate at least twice that of the transfer rate of supply means.
15. A packaging system according to any one of claims 12-14 wherein the supply means and accumulation devices transfer articles in a direction substantially perpendicular to the direction that the infeed conveyor mechanisms transfer the articles.
16. A packaging system according to any one of claims 12-15 wherein there further comprises two filling machines each disposed at the infeed end of each of a pair of supply means, each filling machine for filling the articles, the articles may for example be pouches, bottles or cans, with a product such as a beverage, and wherein each of the filling machine may supply articles to one of the supply means of each pair of supply means.
17. A packaging system according to claim 16 wherein there further comprises a device located on the supply means, for further processing of the articles such as chilling of the articles, application of straws or labels to the articles.
18. A packaging system according to any one of claims 12-17 wherein the article transfer rate of the infeed conveyor mechanisms is 250 ppm and wherein the article transfer rate of the supply means is 125 ppm.
19. A packaging system according to any of claims 12-18 wherein the packaging machine operates at 500 ppm.
20. A packaging system according to any one of claims 12 to 19 wherein the system is capable of inter changing between said pair of accumulation devices to supply articles to each of said infeed conveyor mechanisms such that articles are continuously supplied to the infeed conveyor mechanism.
PCT/US2006/029839 2005-07-29 2006-07-28 Apparatus and method for packaging articles WO2007016531A2 (en)

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GB0515636.9 2005-07-29
GB0515636A GB2429003A (en) 2005-07-29 2005-07-29 Merging accumulated articles from two conveyors

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JPS5969314A (en) * 1982-10-12 1984-04-19 Hitachi Ltd Conflux control method for conveyer
DE29602108U1 (en) * 1996-02-02 1996-03-28 Trapo Stumpf Gmbh Switch for round belt conveyor belts
DE29817239U1 (en) * 1997-11-07 1998-11-26 Paal Kg Hans Intermediate storage device
EP1228986A1 (en) * 2001-02-02 2002-08-07 Daifuku Co., Ltd. Article joining control method

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US6244307B1 (en) * 1998-04-30 2001-06-12 Mitsubishi Heavy Industries, Ltd. Transportation, feeding and filling apparatus of irregular-formed vessels and transportation and feeding method

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3850281A (en) * 1972-04-08 1974-11-26 Focke Pfuhl Verpack Automat Device for bringing together objects being delivered in two lines
JPS5969314A (en) * 1982-10-12 1984-04-19 Hitachi Ltd Conflux control method for conveyer
DE29602108U1 (en) * 1996-02-02 1996-03-28 Trapo Stumpf Gmbh Switch for round belt conveyor belts
DE29817239U1 (en) * 1997-11-07 1998-11-26 Paal Kg Hans Intermediate storage device
EP1228986A1 (en) * 2001-02-02 2002-08-07 Daifuku Co., Ltd. Article joining control method

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GB2429003A (en) 2007-02-14
WO2007016531A3 (en) 2007-05-31

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